ZEISS Research & Quality Solutions has introduced ZEISS TALOS, a metrology robot designed for automated, high-volume inspection. The system combines metrology-grade accuracy with flexible robotic kinematics, and ZEISS specifies measurement uncertainty below 100 µm over a reach of 3.30 meters.
According to ZEISS, the robot positions the sensor precisely and repeatably without external tracking systems or reference markers. That capability is intended to enable reliable measurement of medium-sized and large components, including areas that are difficult to access with conventional line-of-sight measurement systems. A newly developed optical sensor supports both full-field geometry acquisition and precise feature measurement within a single automated workflow.
Integrated robot, sensor and rotation table
The metrology robot ZEISS TALOS MR and the compact blue-light sensor ZEISS TALOS AX form an integrated measurement unit. ZEISS complements the unit with the metrology-grade ZEISS TALOS RT rotation table and the ZEISS TALOS Safeguard safety concept.
Dr. Jan Thesing, Head of Business Unit 3D Optical Systems at ZEISS, said the system marks a fundamental shift in automated metrology because metrological capabilities are integrated directly into the system while the speed, range and flexibility of robotic kinematics are retained.
One sensor for surface and feature measurements
ZEISS says a longstanding challenge in optical metrology is combining fast surface measurement with precise feature measurement. The TALOS AX sensor has two 24-megapixel cameras and captures images at 100 Hz, or up to 200 Hz with fast scan. A 500 mm wide measurement volume and four multidirectional feature flashes allow it to measure large surfaces for geometry analysis and digital twins, as well as precise features such as holes, edges, bolts and threads.
Prepared for production environments
The robot and system concept are designed to withstand typical environmental influences such as temperature variations, vibration and dust, according to ZEISS. Measurement tasks can be prepared offline based on the CAD model, while ZEISS INSPECT automatically calculates the required measurement positions and robot paths. ZEISS says this significantly reduces the time and effort required to plan new measurement tasks. One-click programming, efficient robot motion and streamlined setup are intended to help increase throughput and enable more efficient use of measurement capacity. With ZEISS INSPECT, users can perform complete analyses, generate comprehensive reports and integrate measurement results into existing processes, according to the company.
Automotive and aerospace applications
ZEISS TALOS is designed for automotive, aerospace and commercial vehicle manufacturing applications, both near production and in dedicated measurement rooms. The system supports inspection of car bodies, hang-on parts and giga-casting parts, as well as aerostructures, jet engines, truck cabins and weld seams. High-resolution measurement data enables precise evaluation of component quality and deviations. Virtual tools can be used to assess functional dimensions, gap sizes and flushness, for example in automotive assembly.